Methods and systems for creating aerosols

ABSTRACT

Aerosols can be created by filament stretching and breaking of Newtonian and non-Newtonian fluids by applying a strain to and stretching the fluid. The fluid is stretched along a strain pathway and forms a fluid filament between diverging surfaces. The stretched fluid filament breaks into droplets that can be harvested to form a mist or aerosol. The aerosol creation systems can include one or more pairs of counter-rotating rollers that are positioned adjacent to each other that stretch the fluid or a pair of pistons that move toward and away from each other to stretch the fluid. Some aerosol creation systems can include multiple pairs of counter-rotating rollers that are positioned in a circular, oval, or linear pattern. The aerosol creation system with multiple pairs of counter-rotating rollers can generate mist is one or more directions and can be positioned between two concentric rings or linearly, among other configurations.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to co-pending U.S. patent application Ser.No. 14/066,418, entitled “METHODS AND SYSTEMS FOR CREATING AEROSOLS,”filed on Oct. 29, 2013 and co-pending U.S. patent application Ser. No.14/066,435, also entitled “METHODS AND SYSTEMS FOR CREATING AEROSOLS,”filed on Oct. 29, 2013. Each of these applications is hereinincorporated by reference in their entirety.

BACKGROUND

Many manufacturing and industrial applications benefit from fluidatomization to create a fine vapor mist or aerosol, such as the fuel/airmixture used in combustion applications, atomized air-paint mixtures forspray painting, application of coatings to pharmaceuticals, adhesiveapplications, and the like. Once a component solution is made into anaerosol it can be readily processed to coat virtually any shapedsurface. Alternatively, in the pharmaceutical industry, aerosols arecommonly used in a process called “spray-drying” to create fine powdersthat serve as upstream component solutions to create activepharmaceutical ingredients.

In all known applications, creating the aerosol from a componentsolution is challenging. When the component solution behaves like aNewtonian fluid, the creation of a vapor or aerosol is accomplished by anumber of conventional methods. One conventional method uses highvelocity air flows to entrain air and liquid. A typical atomizer oraerosol involves the coaxial flow of air and component solution at largeReynolds and Weber numbers, i.e., the inertial forces dominate theviscous and surface tension forces in the fluid. Such flows aregenerally unstable and lead to fluid break-up by Kelvin-Helmholtz andPlateau-Rayleigh instabilities. In many instances, the flow is turbulentand chaotic, which strips and stretches the fluid parcels at high strainand strain rates, which leads to the entrainment of large amounts of airwith the fluid and results in a fine mist of drops suspended in the air.

High velocity coaxial flows are effective when the component solutionhas Newtonian properties and behaves like a Newtonian fluid. However,many component solutions contain a variety of macromolecular andinteracting solids components that lead to non-Newtonian properties,including shear-thinning and viscoelasticity. Conventional methods ofatomization like high velocity coaxial flows and electrospray can beineffective for component solutions that have non-Newtonian properties.For example, if a component solution is viscoelastic and stronglyextensionally thickening, its extensional viscosity can increase byseveral orders of magnitude in the straining direction when the fluid isstretched, i.e., greater than 10⁵ for some high molecular weight polymercomponent solutions.

During jetting, the extensional thickening of component solutions havingnon-Newtonian properties causes the viscous drag to overwhelm theinertial and surface tension forces, which allows the system to supportlarge strain before breaking-up and preventing the formation of smalldrops. The jetting leads to the formation of long, sticky filaments,films, and tendrils that never break-up and become suspended in air.Essentially, the liquid stretches, but never breaks into droplets toform a mist or vapor.

The principal problem with coaxial flow systems to create aerosols isthat the straining direction is coincident with the translationdirection. The filament eventually breaks up into droplets to form amist, but to achieve the large strain the filaments issuing from the jetmust necessarily travel long distances. As the filaments travel, thefilaments lose momentum and can recoil to reform large droplets.Alternatively, attempts to continually impel the filament during itstrajectory require impractically long jetting to break the filaments andform droplets.

Therefore, methods and systems that create aerosols from fluids thatshow one or both of Newtonian and non-Newtonian properties would bebeneficial in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a progressive illustration of fluid being drawn through a nipdefined between two rollers and a fluid filament stretching, accordingto aspects of the disclosure.

FIG. 2 is an example of a pair of pistons between which fluid isstretched and breaks.

FIG. 3 shows a pair of counter-rotating rollers and a filament formed ona downstream side of the nip, in accordance with aspects of thedisclosure.

FIG. 4 is a cross-sectional view of an exemplary pair ofcounter-rotating rollers with a fluid reservoir.

FIG. 5 is an example of an aerosol creation machine having a pair ofcounter-rotating rollers that create aerosol.

FIGS. 6A and 6B are two examples of fluid coating techniques for a pairof counter-rotating rollers.

FIGS. 7A-7E are additional examples of fluid coating techniques for apair of counter-rotating rollers.

FIG. 8 is an example a system for creating aerosols that includes fansto create air flow upstream of the pair of counter-rotating rollers.

FIG. 9 is the system for creating aerosols shown in FIG. 8 with theaddition of baffles that are positioned downstream of the pair ofcounter-rotating rollers.

FIG. 10 is the system for creating aerosols shown in FIG. 9 with theaddition of a spray collector and a vacuum that are positioneddownstream of the pair of counter-rotating rollers and the baffles.

FIG. 11 is an example system for creating aerosols that includes airflow that is positioned upstream of the pair of counter-rotating rollersand baffles, a spray collector, and a vacuum that are positioneddownstream of the pair of counter-rotating rollers.

FIG. 12 is another example system for creating aerosols that includes afan positioned below the pair of counter-rotating roller, a bafflepositioned above the counter-rotating rollers, and a spray collector andvacuum positioned downstream of the counter-rotating rollers.

FIG. 13 is yet another example system for creating aerosols thatincludes an air stream that travels parallel to the counter-rotatingrollers along the nip defined between the rollers.

FIG. 14 is an example roller of a counter-rotating roller showingvarious openings on the roller surface.

FIGS. 15A-15C are example textures for one or both of thecounter-rotating rollers.

FIG. 16 is one of the counter-rotating rollers having two regions ofdifferent textured surfaces.

FIG. 17 is yet another example textured surface for a counter-rotatingroller in which ribs spaced apart at varying distances extend around thecircumference of the roller.

FIG. 18 is still another type of textured roller surface in which aplurality of bristles extends away from the surface of the roller.

FIG. 19 is an example roller having two surface treatments applied toits surface in different regions.

FIGS. 20A and 20B are an example system for creating aerosols withmultiple rollers and a three-dimensional perspective view thereof.

FIGS. 21A and 21B are another example system for creating aerosols withmultiple rollers and a three-dimensional perspective view thereof.

FIGS. 22A and 22B are yet another example system for creating aerosolswith multiple rollers and a three-dimensional perspective view thereof.

FIGS. 23A and 23B are still another example system for creating aerosolwith multiple rollers and a three-dimensional perspective view thereof.

FIG. 23C is a blown up view of one of the spacers shown in FIGS. 23A and23B.

FIGS. 24A and 24B are an example system for creating aerosols withmultiple rollers and a three-dimensional perspective view thereof.

FIGS. 25A and 25B are still another example system for creating aerosolswith multiple rollers and a three-dimensional perspective view thereof.

FIGS. 26A and 26B are yet another example system for creating aerosolswith multiple rollers and a three-dimensional perspective view thereof.

DETAILED DESCRIPTION

Systems and methods for creating aerosols are disclosed in which fluidfilaments are stretched and break-up into droplets that create anaerosol, mist, or other vapor. Aerosols, mists, and vapors areinterchangeable terms used to describe one or more droplets of fluidfilaments that become suspended in air. The fluids are often liquids,having either Newtonian or non-Newtonian properties. Generally, fluidshaving non-Newtonian properties can have strong extensional thickening,which cause their extensional viscosity to increase significantly,sometimes several orders of magnitude, in the straining direction whenstrained. The extensional thickening of non-Newtonian fluids causesviscous drag that overwhelms the inertial and surface tension forces ofthe fluid and allows the system to support large strain beforebreaking-up and preventing the formation of small drops or droplets.

If strained and stretched enough along an appropriately long strainpathway, all fluids, including fluids having Newtonian and non-Newtonianproperties, eventually break-up into small droplets and form a mist oraerosol. All fluids can be continually stretched to form fluid filaments(stretched fluid) until the fluid filaments break into several dropletsthus forming a mist or aerosol.

The process of straining and stretching fluid filaments can be repeatedwith excess fluid remaining after the first round of droplets have beenformed or with new fluid. Further, multiple fluid filaments can bestretched in parallel with the first fluid filament stretching andstraining process thus increasing the volume of the formed droplets. Theamount of time between stretching the first fluid filament and anyadditional excess fluid filaments can be defined by a time period thatmay be adjusted or controlled, as desired. The time periods betweenmultiple stretching and breaking of fluid filaments can be variable orcan be constant.

FIG. 1 shows a progression of fluid that is stretched by a pair ofcounter-rotating rollers 100, 102. A nip 104 is defined as the spacebetween the two rollers 100, 102 into which the fluid is drawn when therollers 100, 102 counter-rotate. The fluid pools at an upstream side 106of the nip 104 and is drawn through the nip 104. On a downstream side108 of the nip 104, the fluid is stretched between the surfaces of thetwo rollers 100, 102 into a fluid filament 110. As the rollers 100, 102counter-rotate, the surfaces of the rollers 100, 102 to which the fluidfilament 110 adheres remains the same, but the space between suchsurface is greater. The fluid filament 112 grows longer and thinner asthe surfaces of the rollers 100, 102 rotate away from each other. Whenthe fluid filament 112 reaches a point of the liquid bridge becomingunstable, which is also the capillary break-up point for the fluidfilament 112, the fluid filament 112 breaks up into several droplets 114and leaves excess fluid 116 behind on each of the roller's surface. Theexcess fluid 116 retracts to the surface of its respective roller andcan be part of the fluid that pools and is drawn through the nip on thenext rotation of the rollers. The process can be repeated to provide acontinuous mist.

FIG. 2 shows a progression of fluid 204 that is stretched between a pairof pistons 200, 202 to form a fluid filament 206 that eventually breaksup into a plurality of droplets 206. Fluid 204 is placed between thepistons 200, 202. The pistons 200, 202 are pulled apart and a continuousstrain is applied to cause the fluid 204 to stretch between the pistons200, 202 and form a fluid filament 206. As the fluid filament 206 growslonger and thinner, the fluid filament 206 eventually reaches itscapillary break-up point at which it breaks into multiple droplets 208and leaves excess fluid 210 behind on the surface of each piston 200,202. FIG. 2 also shows a beads-on-a-string structure 212, which is theprecursor to fluid filament 206 reach its capillary break-up point atwhich time the droplets 208 form. Excess fluid 210 is pooled on thepistons 200, 202 and the pistons 200, 202 can be brought back togetherand the fluid stretched again, thereby repeating the process and formingadditional mist droplets.

FIG. 3 shows an example pair of counter-rotating rollers 302, 304. Therollers 302, 304 define a nip 306, which is the region between therollers. In some examples, the nip is defined by the space betweenrollers that are physically spaced apart. In other examples the nip 306is defined between the rollers physically touching each other. In yetother examples, the rollers have a flexible surface material thatcompresses when the rollers contact each other at the nip.

The nip 306 has an upstream side 310 and a downstream side 312. Fluidcoating the roller(s) pools on the upstream side 310 of the nip 306. Thefluid is drawn through the nip 306 to the downstream side 312 andstretched to form a fluid filament 308. The fluid filament 308 has acontinuous and increasing strain applied to it on the downstream side,which causes the fluid filament 308 to grow longer and thinner as thestrain is increased and the surfaces of the rollers 302, 304 are pulledfarther apart. In the example shown in FIG. 3, the strain applied to thefluid filament 308 is increased because of the counter-rotation of therollers 302, 304—the fluid remains attached to the same location on thesurfaces of the rollers and the rollers counter-rotate, which causes agreater distance between the rollers' surfaces as the rotation occurs,thereby stretching the fluid filament until it breaks.

FIG. 4 shows a more detailed view of an aerosol creation system 400having a pair of counter rotating rollers 402, 404. Similar to FIG. 3,the pair of counter-rotating rollers 402, 404 of FIG. 4 define a nip 406therebetween and they counter-rotate with respect to each other. Therollers 402, 404 are both coated with a fluid 412, 414, respectively.The fluid 412, 414 extends around the entire circumference of eachroller 402, 404. Some portion of the fluid 412, 414 on one or bothrollers 402, 404 could partially dry-off leaving areas of the rollersurface(s) without a fluid coating. Alternatively, the fluid can coatonly one of the pair of rollers that could also experience some partialdry-off areas, in other examples.

In FIG. 4, a portion of the lower roller 404 is submerged in a coatingpan 408 that contains the fluid 410 that coats the lower roller 404. Thelower roller 404 also has a rubber layer 416 that enables a negative gapto be implemented between the lower roller 404 and the upper roller 402.The negative gap between the two rollers 402, 404 causes the fluid to bereversibly compressed between the rollers 402, 404. The rubber layer 416also encourages the fluid 410 to adhere to the roller 404 surface. Therubber layer 416 is rubber in this example, but can be any othersuitable material that helps the fluid adhere to the roller in otherexamples.

Between the pair of counter-rotating rollers 402, 404 is a nip 406. Inthis example, the nip squeezes the fluid layers 412, 414 between the tworollers 402, 404 at a controlled fluid thickness. The controlled fluidthickness can be adjustable in some examples or can be fixed in otherexamples. Controlling the fluid thickness controls the volume of andmanner in which the droplets 418 of the mist are formed on thedownstream side of the nip 406. As discussed above regarding FIG. 1, thefluid can pool at the upstream side of the nip 406 before it passesthrough the nip 406. The pooling of fluid in the example shown in FIG. 4can be a combination of the fluid from both rollers 402, 404.

FIG. 5 shows an example of an aerosol creation system 500 having a pairof counter-rotating rollers 502, 504 as a strain element that stretchesthe fluid. A driving element, such as the motors 506 shown in FIG. 5,drive the pair of counter-rotating rollers 502, 504 to rotate incounter-rotation with respect to each other, as indicated by the arrows508, 510 in FIG. 5. A fluid source 511, such as a reservoir with liquidin it, coats one or both of the rollers 502, 504 with a fluid. A film offluid forms on the surface(s) one or both of the rollers 502, 504. Ametering blade 512 or other film thickness control mechanism may beincluded in the filament creation system 500 to control the thickness ofthe film on the roller(s) 502, 504. The metering blade 512 eithercontacts, as shown in FIG. 5, or comes into near contact with one orboth of the rollers 502, 504 to control the thickness of the film offluid on the roller(s) 502, 504.

As discussed above, when the rollers counter-rotate with respect to eachother, the fluid coating one or both of the rollers is drawn into a nipdefined between the rollers. The fluid filament stretches on adownstream side of the nip and breaks into droplets to form the mist onthe downstream side of the nip. The fluid filament breaking intodroplets flows in a direction that is away from the rollers themselves.A harvesting element can be positioned to collect mist that is formed bythe fluid coating being drawn through the nip of the rollers. The mistis a collection of the droplets that are formed by the fluid filamentsbreaking.

FIGS. 6A and 6B show two different types of fluid coating techniques foraerosol creation systems having a pair of counter-rotating rollers thatstretch the fluid. FIG. 6A includes a fluid feed 602 that is directed tocause the fluid to contact the top roller 604 of the pair ofcounter-rotating rollers. The fluid feed 602 causes the fluid to contactthe top roller 604 near where a metering blade 606 also contacts the toproller 602, in this example. The metering blade 606 controls thethickness of the fluid that adheres to the surface of the top roller604. The fluid forms a fluid film around the circumference of thesurface of the top roller 604 as the top roller 604 rotates in acounter-clockwise motion and the metering blade 606 sets a maximumthickness for the fluid film based on how close it is positioned to thesurface of the top roller 604 in this example or either or both rollersin alternative examples.

The counter-rotation of the rollers 604, 610 draws fluid through a nip608 formed between the top roller 604 and the bottom roller 610. Thebottom roller 610 rotates in a clockwise motion, which thereby draws thefluid film through an upstream end of the nip 608. Air flow pathways612, 614 on the downstream side of the nip 608 have a pathway that isparallel to the rotating motion of each respective roller, e.g., for thetop, counter-clockwise rotating roller 604, the airflow pathway 612 isparallel to the counter-clockwise rotation of the top roller 604 and forthe bottom, clockwise rotating roller 610, the airflow pathway 614 isparallel to the clockwise rotation of the bottom roller 610.

FIG. 6B shows another roller coating technique for the same pair ofcounter-rotating rollers 640, 610 shown in FIG. 6A in which the fluidsource is a pan or reservoir 616 with fluid in it. The reservoir 616 ispositioned so that a portion of the bottom roller 610 is submerged inand travels through the fluid in the pan 614 when it rotates, whichencourages or causes fluid to adhere to the surface of the bottom roller610. The metering blade 618 is positioned to contact or nearly contactthe bottom roller 610 and control the thickness of the fluid film thatadheres to the surface of the bottom roller 610 by defining a maximumthickness through which the fluid passes. The airflow pathways 612, 614are the same or similar for the counter-rotating rollers for bothcoating techniques shown in FIGS. 6A and 6B.

The nip 608 shown in the FIGS. 6A and 6B examples includes a gap orspace between the two rollers 604, 610 such that the rollers 604, 610are positioned adjacent to, but not in direct contact with each other.The narrow gap formed by the nip 608 still causes the fluid filaments tostretch on the downstream end of the nip 608 and break into droplets toform a mist or aerosol.

FIGS. 7A-7E show alternative coating techniques for applying fluid tothe roller(s) of strain elements having a pair of counter-rotatingrollers. In these examples, a single roller 700 is shown for clarity,although the rollers are part of a pair of counter-rotating rollers.FIG. 7A shows a fluid source 702 that is applying a slot bead coating tothe roller 700. The fluid source 702 is positioned to apply the fluid tothe surface of the roller 700 on an upstream side of and approximatelymidway along the height of the roller 700. The fluid source 702 is incontact or near contact with the surface of the roller 700 in thisexample. The fluid 704 coats the circumference of the roller 700.

FIG. 7B has a fluid source 706 having a first fluid 708 and a secondfluid 710 that apply a multi-layer slot bead coating to the roller 700.Similar to the single-layer slot bead coating technique discussed inFIG. 7A, the fluid source 706 is positioned to apply the fluid to thesurface of the roller 700 on an upstream side of and approximatelymidway along the height of the roller 700 and is in contact or nearcontact with the surface of the roller 700. However, in this example,the fluid source 706 includes a first fluid 708 and a second fluid 710that are overlaid on each other and are applied as a multi-layer fluid712 to the surface of the roller 700. The multi-layer fluid 712 coatsthe circumference of the roller 700.

FIG. 7C shows a slot curtain coating technique in which the fluid source714 is positioned above and approximately midway along with width of theroller 700. The fluid source 714 is also spaced apart from the roller700 and does not come into physical contact with the surface of theroller 700 in applying the fluid to the roller 700, which causes thefluid to travel a distance through the air before contacting the roller700. The fluid pathway 716 extends around the circumference of theroller in a similar fashion to the other alternative coating techniquesdiscussed above in FIGS. 7A and 7B.

FIG. 7D shows a slide bead coating technique in which the fluid source718 includes a first fluid 720, a second fluid 722, and a third fluid724 that together create a multi-layer fluid 726 that adheres to thesurface of the roller 700. The fluid source 718 is positioned on a sideof and is tilted at an angle with respect to the roller 700 such thatwhen each of the first fluid 720, the second fluid 722, and the thirdfluid 724 are dispensed, they run into each other and form themulti-layer fluid 726. The fluid source 718 in this example ispositioned to dispense the fluid 726 either in contact or in nearcontact with the roller 700. Similar to the other examples discussedabove, the fluid pathway of the fluid 726 extends around thecircumference of the roller 700.

FIG. 7E shows a slide curtain coating technique in which the fluidsource 728 includes a first fluid 730, a second fluid 732, and a thirdfluid 734 that together create a multi-layer fluid 736 that adheres tothe surface of the roller 700. The fluid source 728 is positioned to aside of and is tilted at an angle with respect to the roller 700 suchthat when each of the first fluid 730, the second fluid 732, and thethird fluid 734 are dispensed, they run into each other and form themulti-layer fluid 736. The fluid source 728 is spaced apart from thesurface of the roller 700 and does not come into physical contact withthe surface of the roller 700 in applying the fluid 736 to the roller700, which causes the fluid 736 to travel a distance through the airbefore contacting the roller 700. The fluid pathway extends in thedirection perpendicular to the point of contact between the fluid 736and the roller 700 and coats the roller 700 around its circumference.

Any suitable coating technique(s) can be used to apply fluid to thesurface of a roller and the above discussed coating techniques are notdesigned to limit the disclosure in any way. For example, the fluid canbe applied at any suitable angle and in any suitable location withrespect to the roller(s). The fluid can be dripped on to one or bothrollers or can be directly applied to the roller's surface. The fluidcan be applied on the upstream or downstream side of the nip, althoughin the above examples, the rollers are round and any application offluid on the downstream side of the nip coats the roller on thedownstream side and the roller's rotation causes the fluid to enter thenip on the upstream side of the nip.

FIGS. 8-12 are example configurations for aerosol harvesting systems,each having some aid in forming the droplets of the aerosol or indirecting the mist of the aerosol. Each of FIGS. 8-12 include a pair ofcounter-rotating rollers 800, 802, a fluid source 804, and a meteringblade 806. In another example, an electric field can be applied to ornear the nip to encourage the formation of droplets from the fluidfilaments.

In FIG. 8, the aerosol creation system also includes three fans 808 withrespective air flow pathways 810 that encourage the fluid filaments tostretch and break into droplets on the downstream side of the nipbetween the rollers and to encourage the formed mist or aerosol totravel in the direction of the air flow 810. Alternatively, the fans canbe replaced with any suitable compressed air source or any pressuresource that is able to encourage fluid filaments to stretch and breakinto droplets.

FIG. 9 shows the aerosol creation system shown in FIG. 8 with theaddition of two baffles 812 positioned on the downstream side of the nipand are angled with respect to the rollers 800, 802. The baffles 812guide the formed aerosol into a pathway 814 that travels through anopening 816 formed between the two baffles 812. FIG. 10 is the aerosolcreation system shown in FIG. 9 with the addition of an aerosolcollector 818 and a vacuum 820. The aerosol collector 818 is an elementthat gathers the droplets of the aerosol into a container of anysuitable type. The vacuum 820 may be applied to help encourage thedroplets of the aerosol to travel into the aerosol collector 818 or tootherwise guide the aerosol in a desired direction or along a desiredpathway. FIG. 11 is the same aerosol creation system shown in FIG. 10,but with the fans removed.

FIG. 12 is yet another aerosol creation system having a pair ofcounter-rotating rollers 800, 802, a fluid source 804, and a meteringblade 806. In the example shown in FIG. 12, a fan 822 is positioned onthe downstream side and below the pair of rollers 800, 802 and causes anair flow pathway 824 that is perpendicular to the direction in which theaerosol is directed away from the rollers 800, 802. The air flow pathway824 directs the aerosol toward a baffle 826 that in turn directs theaerosol into an aerosol collector 828. A vacuum 830 may be applied tothe aerosol collector 828 to encourage the aerosol to travel into theaerosol collector 828 in one configuration. In another configuration,the air stream runs through one or both of the rollers and is expelledradially through one or both of the rollers or a portion thereof.

FIG. 13 shows still another aerosol creation system that includes a pairof counter-rotating rollers 1300, 1302. The bottom roller 1302 ispartially submerged in and positioned to rotate through liquid in areservoir 1304. An air stream 1308 flows toward the droplets formed bythe fluid break-up 1306 at the downstream side of the nip, approximatelyparallel with the length of the rollers 1300, 1302.

FIG. 14 shows a roller 1400 having a plurality of openings 1402 in itssurface. The holes draw the fluid into the openings 1402 and control themanner in which the fluid filaments are formed (i.e., the size of thefluid filaments, which also controls the size of the mist droplets),which regulates the manner in which the fluid filament break-up occursand the resulting formation of the mist. The openings 1402 can alsoimprove the fluid adhering to the surface of the roller 1400. Further,the openings 1402 can be either holes through the surface of the rollerthat extend into the interior of a hollow roller or can be openings witha floor, such as a cavity extending inward from the roller surface. Theopenings 1402 increase the surface area to which the fluid adheres tothe roller surface. Having areas of increased fluid volume, such as inthe areas where the fluid pools in the openings 1402 shown in FIG. 14,increases the volume of fluid that can be stretched when the rollerscounter rotate, which in turn increases the amount of droplets that areformed from the fluid filaments reaching their point of capillarybreak-up. One or both rollers can include the openings shown in FIG. 14.The openings 1402 can be in any suitable configuration and can be anysuitable shape and size.

FIGS. 15A-15C show various textures that can be applied to the surfacesof one or both rollers. The textures can be formed integrally with thesurface of the rollers or can be applied as a layer on top of thesurface of the rollers. FIG. 15A shows a textured roller surface havingmultiple dimples. FIGS. 15B and 15C show textured roller surfaces havingpatterned raised elements. The textured surface(s) of the roller(s)increase the surface area of the roller to which the fluid adheres andcan shape or otherwise alter the thickness, shape, flow, angle ofadhering, or the like between the fluid and the surface of the roller.

FIG. 1600 shows a roller 1600 with a textured surface in which a firstportion 1602 of the textured surface has a first texture and a secondportion 1604 of the textured surface has a second texture that isdifferent from the first texture. FIG. 17 shows yet another roller 1700with a textured surface that includes a plurality of ribs 1702 thatextend around the circumference of the roller and are spaced apart atvarious distances from each other. FIG. 18 is still another exampleroller 1800 having multiple bristles 1802 that extend away from thesurface of the roller 1800.

FIG. 19 is yet another roller 1900 that has a first region 1902 that istreated with a first surface treatment to change the angle at which thefluid contacts the roller 1900 and a second region 1904 that is treatedwith a second surface treatment that changes the angle at which thefluid contacts the roller 1900 in a manner different from the firstsurface treatment. In other examples, only a single surface treatment isapplied to the roller that changes the angle at which the fluid contactsthe roller.

The texture and/or the treatment applied to the rollers can be selectedbased on the characteristics of the fluid that is aerosolized tocustomize the aerosol creation process to each fluid and provide themost efficient manner for aerosolizing the fluid among other reasons. Insome examples, the textured surface of one or both of the rollers variesthe thickness of the fluid coating that adheres to the surface of theroller. Such a textured surface can help vary the thickness of the fluidfilm in a manner that increases the efficiency of the fluid filamentbreaking into droplets by varying the concentration of the fluid intarget regions.

The rollers can include any suitable materials such as steel or othermetal(s), plastics, rubbers, or the like. The rollers or any portionsthereof also can be a single material or may be any number of multiplematerials. For example, a roller can have a core material that is coatedwith or includes a surface layer of a material that is softer than thecore material. In some examples, the surface layer material encouragesthe fluid to adhere to the roller or may encourage the fluid to adhereto the roller at a different angle or in a different way than wouldoccur without the surface layer material.

The orientation of the fluid source with respect to the rollers can beany desirable position. Some of the above examples discuss an air flowsource that directs the droplets forming the mist or aerosol in aparticular direction. The air flow source can be any gas source and isnot limited to air. For example, the gas source can be positioned tocause gas to flow on either side of, above, or below the nip toencourage or cause the formation of droplets from breaking of the fluidfilaments. Alternatively, the gas source can be positioned to cause gasto run through one or both rollers so the gas is expelled radially fromthe roller(s).

The formed mist can be directed to form an aerosol of variousgeometries. Any desirable geometrical shape can be formed, depending onhow the mist is directed. The geometry can be any shape, such as arectangle, cone, or conical shape and the size and contour of suchshapes can be controlled by altering the volume and concentration of theaerosolized fluids.

The above two-roller and piston configuration aerosol creation systemsinclude a pair of rollers or pistons that produce an associatedconcentration of fluid mist. Some disclosed methods of increasing theconcentration of the mist include parallelizing the systems and creatinga greater concentration of stretched fluid filaments and thus theproduced mist. FIGS. 20A-26B shows some example systems 2000, 2100,2200, 2300, 2400, 2500, 2600, their associated three-dimensional views,methods of producing higher concentrations of the fluid mist and includesystems and methods with multiple rollers and their respective divergingsurfaces.

The example multi-roller systems and methods have a first roller and afirst diverging surface and a second roller and a second divergingsurface. A first nip is defined between the first roller and the firstdiverging surface and a second nip is defined between the second rollerand the second diverging surface. Each nip has an upstream side and adownstream side, in a similar manner as discussed above in regards tothe two-roller and piston example systems. Fluid is drawn through eachnip toward the downstream sides of each nip. The fluid is stretched intofluid filaments on the downstream sides of each nip between the surfaceof the respective roller and the respective roller's diverging surface.The stretched fluid filaments are caused to break into a plurality ofdroplets in the same manner discussed above regarding thetwo-roller/piston systems, e.g., by overcoming the fluid's capillarybreak-up point and causing the fluid filament to break into a pluralityof droplets. The plurality of droplets form a mist that can be harvestedor directed in any manner disclosed herein.

In some examples, the first diverging surface and the second divergingsurface are other rollers, such as the examples shown in FIGS. 20A, 20B,21A, and 21B. In other examples, the first diverging surface and thesecond diverging surface are a contiguous ring, positioned in aninterior space within rollers configured in a circular pattern orpositioned to extend along an exterior diameter of rollers configured ina circular pattern, such as the examples shown in FIGS. 22A, 22B, 23A,23B, 24A, 24B, 25A, and 25B. In still other examples, the firstdiverging surface and the second diverging surface are a belt thatsurrounds the multiple rollers, such as the aerosol creation systemshown in FIGS. 26A and 26B.

The multi-rollers aerosol creation systems also include a fluid sourcethat coats the first roller and the second roller with the fluid. Adriving element is structured to drive the first roller and the secondroller to rotate with respect to each other. In some examples, the firstroller and the second roller counter-rotate with respect to theirrespective diverging surfaces, such as the example aerosol creationssystems shown in FIGS. 20A, 20B, 21A, and 21B. In other examples, thefirst roller and the second roller co-rotate with respect to theirrespective diverging surfaces, such as the examples shown in FIGS. 22A,22B, 23A, 23B, 24A, 24B, 25A, and 25B. Any suitable number of rollersand respective diverging surfaces can be included in the multi-rollersystems.

FIGS. 20A, 20B, 21A, and 21B show example systems 2000, 2100 having sixrollers that counter rotate with respect to each other, in analternating fashion in which three rollers 2002 rotate clockwise andthree alternating rollers 2004 rotate counter-clockwise. In bothexamples shown in FIGS. 20A, 20B, 21A, and 21B, each of the six rollers2002, 2004 is driven and can be coated with the fluid in any mannerdescribed above regarding any of the single roller and diverging surfaceexamples. For example, the rollers 2002, 2004 can be coated by aslot-coating method in the systems 2000, 2100 shown in FIGS. 20 and 21or by a pressure method such as pressurizing the downstream sides of thenips.

The six rollers in FIGS. 20A, 20B, 21A, and 21B are positioned in acircular configuration with respect to each other although they can bepositioned in other configurations as desired. The circularconfiguration defines an interior space between the rollers and anexterior diameter surrounding the rollers. Each of the rollers rotatesin counter-rotation with respect to its neighboring roller. Any suitablestructure can support the rollers to be positioned in the circularconfiguration, such as stationary shafts that hold each roller in itsrespective position and drive the rollers to rotate. FIG. 20B shows twosupporting walls positioned respectively at opposite ends of the rollersthat each help hold the rollers in place. Alternatively, a wall or othersupporting structure, such as a spacer, can be positioned in either orboth of along the exterior diameter of the rollers or within theinterior diameter or interior space of the rollers. Other alternativeconfigurations include, but are not limited to, an oval configuration orsome other round or curved configuration. The disclosed multi-rollersystems can include rollers with any desired materials, texturing, andsurface treatments, such as the examples discussed above for thetwo-roller/piston systems.

In FIGS. 20A and 20B, three 2002 of the six rollers are coated with afluid from a fluid source 2010. The fluid source 2010 is positioned inthe interior space 2006 of the circular configuration of the sixrollers. The fluid source 2010 coats every other roller 2002 in thecircular configuration of the six rollers, although in alternativeexamples the fluid source coats every roller or any suitable number ofrollers. The fluid coats the three rollers 2004 and is drawn through anip 2012 defined between alternating sets of counter-rotating rollers.Each nip 2012 has an upstream side and a downstream side and draws fluidthrough the nip 2012 toward a downstream side. The fluid filament 2011is stretched between respective surfaces of the coated rollers 2004 andthe alternating non-coated rollers 2002 on the downstream sides of thenips 2012. The fluid filaments 2011 are caused to break into a pluralityof droplets on the downstream sides of each of the nips 2012.

The plurality of droplets travels in a direction away from thedownstream side of the nips 2012. In the example shown in FIGS. 20A and20B, three arrows 2014 show the direction the plurality of dropletstravel. The formed droplets can be harvested and directed in any mannerdiscussed above.

FIGS. 21A and 21B show another example six roller aerosol creationsystem 2100 in which clockwise rotating rollers 2102 are coated with afluid from the exterior diameter 2108 of the circular configuration ofthe rollers 2102, 2104. The three coated rollers 2102 rotate clockwisein FIGS. 21A and 21B, which is the opposite rotation of the rollers 2004coated in the example system shown in FIGS. 20A and 20B. The upstreamsides of the nips 2112 in the system shown in FIGS. 21A and 21B arepositioned on the exterior diameter 2108 and the downstream sides of thenips 2112 are positioned within the interior space 2106 between the sixrollers 2102, 2104.

The configuration with the three clockwise-rotating rollers 2102 beingcoated along the exterior diameter cause the fluid to be stretchedbetween surfaces of neighboring rollers on the downstream side of thenips 2112 and within the interior space 2106 of the circularconfiguration of the rollers 2102. The fluid filaments 2111 are causedto break into a plurality of droplets within the central interior space2106 of the circular configuration of the rollers, in this example. Thedroplets break in a direction away from the downstream sides of eachnip. As in the example shown in FIGS. 20A and 20B, the formed dropletscan be harvested and directed in any manner discussed above in regardsto the two roller/piston examples. FIG. 21B shows an example supportingstructure that has two walls positioned at both ends of the rollers tohold the rollers in place during rotation.

FIGS. 22A and 22B show still another example aerosol creation system2200 having seven rollers 2202 that are positioned in a circularconfiguration. Each of these rollers 2202 are spaced apart from eachother and co-rotate. The rollers are positioned within a ring 2204, orany other supporting structures in alternative examples, that alsoco-rotates with the rollers 2202. The diverging surfaces of each set ofrollers shown in FIGS. 22A and 22B is a surface of a ring against asurface of each roller. The diverging surface of the aerosol creationsystem 2200 shown in FIGS. 22A and 22B is the same surface for eachroller—the exterior ring 2204 that surrounds the six rollers 2202 anddefines an exterior diameter around the circular configuration of therollers 2202. The seven rollers 2202 rotate by slipping along an innersurface 2206 of the exterior ring 2204 with respect to each other.

The exterior ring 2204 can include the fluid source that coats one ormore of the rollers shown in FIGS. 22A and 22B. The fluid source cancoat the rollers through slots in the exterior ring, in some examples,or any other suitable coating method. The rollers can also be coated bythe slip coating methods discussed above in which the fluid source ispositioned within the central interior space of the circularconfiguration of the rollers opposite the ring. The rollers are spacedapart from each other along the inner surface of the ring. Thus, therollers 2202 can slip along the inner surface 2206 of the exterior ring2204 as they rotate. The rollers 2202 physically contact the innersurface of the exterior ring 2204, in some examples it may even be apositive gap, and in other examples the rollers are positioned slightlyapart from the inner surface of the ring. The fluid is stretched betweenthe inner surface 2206 of the exterior ring 2204 and the surface of eachroller 2202 to create fluid filaments 2211 that are caused to break intoa plurality of droplets.

In some examples, such as the aerosol creation system 2300 shown inFIGS. 23A and 23B, an interior ring 2310 or other round structure ispositioned concentrically within the exterior ring 2304 and each of therollers 2302 is positioned between the interior ring 2310 and theexterior ring 2304. The rollers 2302 are stationary with respect to theinterior ring 2310 and are in direct contact with the outer surface 2312of the interior ring 2310. The driving element can be structured todrive the rollers 2302 to rotate by applying power to the interior ring2310, which causes the rollers 2302 to slip along the inner surface 2314of the exterior ring and stretch fluid on downstream sides of eachrollers and diverging surface combination's nip. The inner surface ofthe exterior ring is each roller's diverging surface in this example.

In the examples shown in FIGS. 23A and 23B, the aerosol creation systemsinclude a combination fluid source and doctoring blade element 2316. Thecombination fluid source and doctoring blade element 2316 can also serveas a spacer to space apart the rollers 2302. The combination fluidsource and doctoring blade element 2316 includes a fluid source thatcoats the surface of the rollers from its location between the rollers.However, the rollers in FIGS. 23A and 23B and any other exampleddiscussed herein can be coated from any location upstream of the nip.FIG. 23C shows a close up view of the combination fluid source anddoctoring blade element 2316 that includes a fluid source 2318, adoctoring blade 2320, and a spacer 2322.

FIGS. 23A and 23B show an aerosol creation system 2300 in which theexterior ring 2304 can be stationary or could rotate and is in directphysical contact with the six rollers 2302. The interior ring 2306 isconcentrically positioned within the exterior ring 2304 and the rollers2302 are positioned between the interior ring 2306 and the exterior ring2304. The rollers 2302 can be spaced apart from the outer surface 2308of the interior ring 2306 and each other to allow the rollers 2302 toslip along the surface 2308. Each roller's nip 2310 is defined betweenthe surface of the roller 2302 and the outer surface 2308 of theinterior ring 2306. The outer surface 2308 of the interior ring 2306 iseach roller's diverging surface in this example. Fluid is drawn throughthe nip and is stretched on the downstream side of the nip to form afluid filament 2311 that ultimately breaks into a plurality of droplets.

The rollers 2302 are positioned in direct contact with and stationarywith respect to the inner surface 2310 of the exterior ring 2304 in FIG.23 and spaced apart from the outer surface 2308 of the interior ring2306 and each other to facilitate slip between the rollers 2302 and theouter surface 2308 of the interior ring 2306. The driving element of theaerosol creation system 2300 shown in FIGS. 23A and 23B can bestructured to apply power to the exterior ring 2304, which causes therollers 2304 to slip along the outer surface 2308 of the interior ring2306 and stretch the fluid on the downstream sides of each roller's nip2308. The rollers and/or the exterior ring co-rotate. The interior ringcan either be stationary or could counter-rotate with respect to therollers and the exterior ring.

FIGS. 24A and 24B show yet another example multi-roller aerosol creationsystem 2400 with five rollers 2402 in a circular configuration. A ring2404 extends around all five of the rollers 2402 in this example. Thering 2404 can include the fluid source 2406. In this example, therollers 2202 are positioned to physically touch each other in a circularconfiguration and are spaced apart from the ring 2404. The fluid sourceis the fluid 2406 housed in the space between the rollers 2402 and thering 2404. In this example, the downstream sides of the nips arepositioned within the central interior space 2408 defined within thecircular configuration of the rollers 2402. The fluid filaments 2410break in a direction toward the central interior space 2408.

FIGS. 25A and 25B show still another example multi-roller aerosolcreation system 2500 with six rollers 2502 positioned in a circularconfiguration around a central ring 2504. The rollers 2502 co-rotate andare spaced apart from each other. The nips are defined between thesurface of each roller and the exterior surface of the central ring2504. The fluid filaments 2510 stretch and eventually break across thedownstream side of each nip. In the example shown in FIGS. 25A and 25B,the fluid source 2506 and the doctoring blade 2508 are each positionedon the upstream side of each nip 2511.

FIGS. 26A and 26B show yet another example multi-roller aerosol creationsystem 2600 having five rollers 2602 in a linear configuration. A belt2604 surrounds the rollers 2602. The rollers 2602 are spaced apart fromeach other and the combination belt 2604 and rollers 2602 are partiallysubmerged in a tray 2606 that contains fluid. Either the belt or therollers rotate. In this example, however, the rollers co-rotate withrespect to each other and the belt in stationary. The nip 2608 is formedbetween the surface of the roller and the interior surface of the upperportion of the belt 2604. The fluid is drawn through the nip 2608 and isstretched into a fluid filament 2610 on the downstream side of the nip2608 until is breaks into a plurality of droplets. Although not shown inthis example, a doctoring blade or other thickness controlling mechanismcan be included to control the thickness of the fluid entering the nipon the upstream side.

The diverging surface for each roller 2602 is a portion of the innersurface of the belt 2604. As the belt 2604 rotates, it causes therollers 2602 to also rotate. Because the rollers 2602 are partiallysubmerged in the fluid, the rotation of the rollers 2602 causes thefluid that coats each roller 2602 to be drawn through each roller'srespective nip 2608 and stretched between the surface of the roller 2602and the portion of the inner surface of the belt 2604 that correspondsto each roller 2602 and forms each roller's nip 2608. As with theexamples discussed above, the fluid is stretched into a fluid filament2610 and ultimately breaks into a plurality of droplets of the fluid.The belt can include any suitable materials including right andsemi-rigid materials. The belt configuration of the aerosol creationsystem 2600 shown in FIGS. 26A and 26B are shown in a horizontalarrangement, but can be other arrangements, as desired, such as curved,vertical, or the like.

All of the example multi-roller aerosol creation systems shown in FIGS.20A-26B can further include any harvesting, directing, or otherwisemanipulated in any manner discussed in this disclosure. Still further,all of the example multi-roller aerosol creation systems shown in FIGS.20A-26B can include any suitable number of rollers and can includealternative configurations. For example, the rollers in the examplesshown in FIGS. 20A-23B can be positioned in an oval or other roundconfiguration and can include any even number of rollers. In anotherexample, the aerosol creation system shown in FIG. 24A can include anynumber of rollers, even or odd, and can be a horizontal or curvedconfiguration.

Increasing the number of rollers in the multiple roller aerosol creationsystems shown in FIGS. 20A-26B increase the number for stretched fluidfilaments that break into the plurality of droplets of fluid and thusthe volume of the formed mist. Varying the configuration of the rollersand the type of diverging surface that when combined with the rollersurface defines each nip varies the direction of travel of the pluralityof droplets formed when the fluid filaments break. Surface treatments ofeach surface that contacts the rollers, the diverging surfaces, and/orthe fluid can also alter or otherwise control the manner in which thedroplets are formed.

Any portion of the aerosol creation systems described above can bepressurized to help draw fluid through any respective nip. For example,providing a higher pressure on the upstream sides of the nips relativeto the downstream sides of the nips helps draw fluid through the nips tobe stretched into fluid filaments and broken into droplets. As discussedabove, any system of controlling the thickness of the fluid as the fluidis drawn through each nip can be included in any of the describedaerosol creation systems. For example, a doctoring blade or doctoringroller can be positioned near the roller as it rotates on the upstreamside of its nip to control and make uniform the thickness of the fluidcoating the roller as it is drawn into the nip. Controlling thethickness of the fluid being drawn into the nip controls theconcentration and volume of droplets formed after the fluid filament isbroken on the downstream side of the nip.

It will be appreciated that variations of the above-disclosed systemsand methods for creating aerosols and other features and functions, oralternatives thereof, may be desirably combined into many otherdifferent systems, methods, or applications. Also various presentlyunforeseen or unanticipated alternatives, modifications, variations, orimprovements therein may be subsequently made by those skilled in theart.

1. An aerosol creation system, comprising: a first roller; a secondroller spaced apart from the first roller in a linear configuration; abelt defining an interior belt space and having an interior surface, thefirst roller and the second roller positioned within the interior beltspace such that at least a portion of a surface of the first roller andat least a portion of the surface of the second roller are in physicalcontact with an interior surface of the belt; a first nip definedbetween the at least the portion of the surface of the first roller thatis in physical contact with the interior surface of the belt, the firstnip having an upstream side and a downstream side; a second nip definedbetween the at least the portion of the surface of the second rollerthat is in physical contact with the interior surface of the belt, thesecond nip having an upstream side and a downstream side; a fluid sourcestructured to coat the first roller and the second roller with a fluid;a driving element structured to drive the first roller and the secondroller to cause fluid to be drawn through the upstream side of the firstnip to the downstream side of the first nip and through the upstreamside of the second nip to the downstream side of the second nip; whereina first fluid filament is stretched between diverging surfaces of thefirst roller and the interior surface of the belt when at least one ofthe belt and the first roller rotates, the first fluid filamentstretched until it breaks into a plurality of first droplets, andwherein a second fluid filament is stretched between diverging surfacesof the second roller and the interior surface of the belt when at leastone of the belt and the second roller rotates, the second fluid filamentstretched until it breaks into a plurality of second droplets.
 2. Theaerosol creation system of claim 1, wherein the first roller and thesecond roller are configured to co-rotate within respect to each other.3. The aerosol creation system of claim 1, wherein the interior beltspace is pressurized to cause pressure on the upstream sides of thefirst nip and the second nip to be greater than the pressure on thedownstream sides of the first nip and the second nip.
 4. The aerosolcreation system of claim 1, wherein the first roller and the secondroller are structured to remain stationary and the belt rotates.
 5. Theaerosol creation system of claim 1, wherein the belt includes a flexibleor semi-flexible material.
 6. The aerosol creation system of claim 1,wherein the belt is structured to remain stationary and the first rollerand the second roller are structured to co-rotate.
 7. The aerosolcreation system of claim 1, wherein the belt, the first roller, and thesecond roller are structured to co-rotate.
 8. The aerosol creationsystem of claim 1, wherein the fluid source is a tray that containsfluid, and wherein a lower portion of the first roller, a lower portionof the second roller, and a lower portion of the belt are submerged inthe tray.
 9. The aerosol creation system of claim 1, wherein a distancebetween the first roller and the second roller is adjustable.
 10. Theaerosol creation system of claim 1, further comprising a third roller,spaced apart from the second roller on the opposite side of the firstroller, the first roller, the second roller, and the third rollerconfigured in a linear arrangement.
 11. A method of creating an aerosol,comprising: drawing a fluid from a fluid source through an upstream sideof a first nip, the first nip defined between a first roller and aninterior surface of a belt within which the first roller is positioned;drawing the fluid from the fluid source through an upstream side of asecond nip, the second nip defined between a second roller and theinterior surface of the belt, the second roller spaced apart from thefirst roller in a linear configuration; stretching the fluid betweendiverging surfaces of the first roller and the interior surface of thebelt on a downstream side of the first nip to form a first fluidfilament; stretching the fluid between diverging surfaces of the secondroller and the interior surface of the belt on the downstream side ofthe second nip; causing the first fluid filament to break into aplurality of first droplets; and causing the second fluid filament tobreak into a plurality of second droplets.
 12. The method of claim 10,wherein the belt defines an interior space within which the first rollerand the second roller are positioned, and further comprising causing apressure on the upstream sides of the first nip and the second nip to begreater than a pressure on the downstream sides of the first nip and thesecond nip.
 13. The method of claim 10, wherein the drawing the fluidfrom the fluid source through the upstream side of the first nipincludes coating the first roller with the fluid, and wherein thedrawing the fluid from the fluid source through the upstream side of thesecond nip includes coating the second roller with the fluid.
 14. Themethod of claim 12, wherein the coating the first roller with the fluidincludes submerging a lower portion of the first roller in a tray withthe fluid, and wherein coating the second roller with the fluid includessubmerging a lower portion of the second roller in a try with the fluid.15. The method of claim 10, further comprising co-rotating the firstroller and the second roller, the co-rotating of the first rollercausing the stretching of the fluid between diverging surfaces of thefirst roller and the interior surface of the belt and the co-rotating ofthe second roller causing the stretching of the fluid between divergingsurfaces of the second roller and the interior surface of the belt. 16.The method of claim 10, further comprising causing the belt to co-rotatewith the first roller and the second roller, the co-rotation of the beltand the first roller causing the stretching of the fluid betweendiverging surfaces of the first roller and the interior surface of thebelt and the co-rotating of the second roller and the belt causing thestretching of the fluid between diverging surfaces of the second rollerand the interior surface of the belt.